Technological breakthroughs

By utilising surplus saturated steam from the formalin production line to provide heat for the UF/UMF resin line, Ms. Nguyễn Thị Hà, Director of the Centre for Scientific and Technological Production Experimentation at the Vietnam Institute of Industrial Chemistry, delivered benefits worth VND 761 million in the first year of implementation. The initiative contributed to energy savings, reduced production costs, and emission mitigation, and was awarded the Creative Labour Certificate by the Vietnam General Confederation of Labour in 2025.

Originating from the need to control costs and improve energy efficiency in production, Ms. Nguyễn Thị Hà researched and proposed the initiative to use surplus saturated steam from the 10,000-tonne-per-year formalin line as a heat source for the UF/UMF resin line of equal capacity, completely replacing the coal-fired boiler.

Previously, the UF/UMF resin line used a coal-fired boiler, consuming around 60 tonnes of coal annually. In addition to fuel costs, the system incurred labour, maintenance, and depreciation expenses. The coal combustion process also generated emissions and solid waste, affecting the working environment.

Meanwhile, the formalin line operated continuously and produced a surplus of saturated steam that had not been effectively utilised. From this reality, Ms. Nguyễn Thị Hà studied the feasibility of recovering and distributing steam between the two lines, converting surplus energy into process heat.

The solution was implemented by assessing the technological characteristics of both lines, evaluating the potential for energy recovery from the formalin exhaust treatment system, and designing a system for steam collection, accumulation, and distribution. Operating regimes and steam coordination procedures were also developed to ensure a stable, continuous supply that met technological requirements without affecting product quality, productivity, or safety on either line.

A highlight of the initiative was the creation of a closed-loop energy circulation system within the factory. Instead of using coal to generate steam for UF/UMF resin production, surplus steam from formalin manufacture was harnessed. The solution not only changed the method of heat supply but also optimised energy use, improving the utilisation of existing equipment and resources.

The economic efficiency of the initiative is clearly demonstrated by annual cost savings: VND 420 million in fuel, VND 360 million in boiler operation labour, VND 20 million in maintenance and replacement, and VND 100 million in equipment depreciation. Total annual savings reached VND 900 million. After deducting VND 139 million for investment in the steam accumulator system, the initiative returned a net benefit of VND 761 million in its first year.

Beyond financial results, replacing the coal-fired boiler has reduced fossil fuel consumption, limited industrial emissions and solid waste, and contributed to a better working environment. The model of energy transfer between two production lines is also a practical solution for promoting circular economy practices, efficient resource use, and green manufacturing at the unit.

In recognition of these achievements, Ms. Nguyễn Thị Hà’s initiative received the Creative Labour Certificate from the Vietnam General Confederation of Labour in 2025, along with a VND 10 million award. This recognition is well-deserved for her commitment to research, innovation, and applying scientific and technological advances to production.

The initiative delivers tangible results not only for the Vietnam Institute of Industrial Chemistry but also demonstrates the potential for energy saving and emission reduction through the internal utilisation of available resources. It contributes to spreading the movement of creative labour, driving technological innovation, and advancing the sustainable development objectives of Vietnam National Chemical Group.